JP6553903B2 - Manufacturing method of resin molded article - Google Patents

Description

The present invention relates to a novel production how a resin molded article with a hollow structure.

  Conventionally, in various fields, resin molded products have been adopted because they are advantageous for weight reduction and improvement of mass productivity, etc. In recent years, resinification of structural members and the like for which strength is required by fiber reinforced resin is also possible. It is in progress.

  By the way, it is advantageous to adopt a hollow cross-sectional structure in order to reduce the weight and reduce the material while ensuring the bending strength and rigidity in the various longitudinal members, thereby reducing the cross-sectional area while suppressing the cross-sectional area. It becomes possible to secure moment and section modulus.

  However, resin molded products that are generally manufactured by molding by filling a molding cavity with a resin material and adopting a long hollow cross-section are difficult to mass-produce due to the problem of removal of the core after molding. The For example, it is conceivable to employ a core molded from a low melting point metal and melt and remove the core after resin molding. However, the core must be molded every time the resin is molded, and the manufacturing process becomes complicated. Due to the increased manufacturing cost, mass production was difficult.

  Therefore, conventionally, as described in Japanese Patent No. 3705384 (Patent Document 1), it is described in a solid resin member composed of a plurality of parts, or in Japanese Patent Laid-Open No. 1-215533 (Patent Document 2). As described above, resin members having an extremely simple shape such as a straight pipe have been employed, and it has been difficult to achieve resinization of various members.

Patent No. 3705384 JP-A-1-215533

  The present invention has been made in the background of the above-mentioned circumstances, and the problem to be solved is a novel method for producing a resin molded article having a hollow structure, which can realize excellent mass productivity. To provide.

  Hereinafter, the aspect of this invention made | formed in order to solve such a subject is described. In addition, the component employ | adopted in each aspect as described below is employable by arbitrary combinations as much as possible.

A first aspect of the present invention is a hollow structure and has been elongated in the method for producing a resin molded article, an elastic core having a longitudinal hollow cylindrical shape composed of a complex between the elastic member and the continuous yarn Yes, the continuous yarn has a braided structure or a spiral structure and is integrated in an embedded state in an intermediate portion in the thickness direction of the elastic body so that it is continuous in the circumferential direction of the elastic body and covers the entire length in the longitudinal direction. used as the continuously extends Te, after molding a resin material on the outer peripheral surface of the elastic core is withdrawn longitudinally exerts a tensile force to one end of the longitudinal elastic core By this, the manufacturing method of the resin molded product which obtains the longitudinal-shaped resin molded product made into the hollow structure is characterized.

  According to the manufacturing method of this aspect, by using an elastic core consisting of a composite of an elastic body and a continuous yarn as a core for resin molding, tensioning from one end side to the elastic core after resin molding When a force is applied, such tensile force is efficiently transmitted along the length of the elastic core through the continuous yarn. As a result, the tensile force is efficiently exerted on the elastic core to the back in the length direction, and the cross-sectional area is reduced and deformed inside the hollow-shaped longitudinal resin molded product. The release of the elastic core from the inner surface is promoted, and the elastic core can be easily pulled out from the longitudinal resin molded product in the length direction.

  Moreover, since the pulled elastic core is elastically restored to its original shape by releasing the tensile force, it can be reused repeatedly during the molding of the next resin molded product.

Therefore, according to the method of the present invention, it is possible to produce a resin molded article having a hollow cross-section which has been difficult in the past with excellent mass productivity. In addition, according to the manufacturing method of this aspect, the continuous yarn arranged to be inclined with respect to the length direction of the elastic core is deformed in a direction in which the inclination angle is reduced by the action of the tensile force. On the other hand, the compressive force that reduces the cross-sectional area as well as the tensile force can be efficiently transmitted in the length direction. As a result, at the time of mold release after resin molding, the elastic core can be more effectively reduced in diameter over the entire length and pulled out.

  According to the manufacturing method of this aspect, the elastic core has a hollow cross section, so that when the elastic core is subjected to a tensile force after resin molding, the outer peripheral length becomes smaller in the cross section of the elastic core. Is more easily generated. Therefore, the elastic core can be pulled out from the resin molded product with a smaller tensile force and released.

According to a second aspect of the present invention, in the method for producing a resin molded product according to the first aspect, when the resin material is molded on the outer peripheral surface of the elastic core, an incompressible amorphous shape is formed in the hollow. A resin molded product is manufactured by filling an incompressible filler.

  According to the manufacturing method of this aspect, even when the filling pressure of the resin material is exerted on the outer peripheral surface of the elastic core when molding the resin material, careless deformation of the elastic core is suppressed. The shape and dimensions of the inner peripheral surface of the molded resin molded product can be stabilized and the accuracy can be improved. In addition, it becomes easy to fluidly take out from the inside of the hollow of the elastic core after resin molding by adopting an indeterminate filler such as liquid or granular solid as the incompressible filler. Therefore, after the incompressible filler is removed from the elastic core to make it easy to reduce the cross-sectional deformation of the elastic core, a tensile force can be applied to the elastic core to pull it out of the resin molded article. .

According to a third aspect of the present invention, in the method for producing a resin molded product according to the first or second aspect, the resin molded product is formed from a fiber reinforced resin obtained by fiber-reinforced the resin material.

  According to the manufacturing method of this aspect, as will be described later, a resin molded product made of a synthetic resin material appropriately reinforced with reinforcing fibers such as carbon fibers, aramid fibers, and glass fibers can be manufactured with a hollow structure. Thus, by securing the required strength and rigidity by fiber reinforcement, it becomes possible to manufacture a resin molded product with a wider application range.

According to a fourth aspect of the present invention, when a fiber-reinforced resin molded article is manufactured according to the third aspect, reinforcing fibers made of continuous fibers are arranged on the outer peripheral surface of the elastic core, and the resin material is molded by molding. The resin molded product comprising the fiber reinforced resin reinforced with reinforcing fibers is obtained.

  According to the manufacturing method of this aspect, since the resin molded product molded on the outer peripheral surface of the elastic core is fiber-reinforced by continuous fibers, it is more strong than discontinuous fiber reinforcement such as short fibers and long fibers. A large resin molded product can be realized.

According to a fifth aspect of the present invention, in manufacturing a fiber-reinforced resin molded product according to the fourth aspect, a plurality of continuous fibers are braided on the outer peripheral surface of the elastic core while curving and deforming the elastic core. It is arranged to cover.

  According to this aspect, by appropriately curving and deforming using the elasticity of the elastic core, for example, the surface of the elastic core having a differently shaped portion such as a curved portion, a bent portion, or a branch portion is also supplied from the outer periphery It is possible to guide and distribute a plurality of continuous fibers. As a result, even when manufacturing a resin molded product having a complicated shape having an irregular shape such as a curved portion, the continuous fiber is made to have an outer periphery of the elastic core with an efficient reinforcement mode such as braided braid braid or spiral braid. It is feasible to arrange the surface and the resin molded product.

In this case, when obtaining a resin-molded article reinforced with reinforcing fibers consisting of continuous fibers, the molding suitably adopted depending on the case where the resin material to be adopted is a thermosetting resin and the case where it is a thermoplastic resin. The process is different. In particular, when a thermosetting resin is employed, the following sixth to seventh embodiments are preferably used. On the other hand, when a thermoplastic resin is employed, the following eighth to tenth embodiments are manufactured. The method is preferred.

That is, the sixth aspect of the present invention uses a thermosetting resin as the resin material when producing a fiber-reinforced resin molded article with continuous fibers according to the fourth or fifth aspect, and uses the thermosetting resin. After the impregnated continuous fibers are arranged on the outer peripheral surface of the elastic core in a covered state, the thermosetting resin is cured to obtain the resin molded product made of the fiber reinforced resin.

In addition, the seventh aspect of the present invention uses a thermosetting resin as the resin material when producing a fiber-reinforced resin molded article using continuous fibers according to the fourth or fifth aspect. After the resin is disposed on the outer peripheral surface of the core in a coated state, the continuous fiber is impregnated with the thermosetting resin during the molding of the thermosetting resin, and the resin is cured by a curing treatment. It is what you get.

On the other hand, in the eighth aspect of the present invention, the thermoplastic resin is used as the resin material to produce a fiber-reinforced resin molded article when producing a fiber-reinforced resin molded article by continuous fibers according to the fourth or fifth aspect. The resin molded article made of the fiber-reinforced resin is obtained by arranging the resin together with the continuous fibers on the outer peripheral surface of the elastic core in a covering state, and then subjecting the thermoplastic resin to a melt molding treatment.

In addition, the ninth aspect of the present invention provides the thermoplastic resin in the form of powder by using a thermoplastic resin as the resin material when producing a fiber-reinforced resin molded article using continuous fibers according to the fourth or fifth aspect. After the resin is attached to the continuous fibers and disposed on the outer peripheral surface of the elastic core in a covered state, the thermoplastic resin is melt-molded to obtain the resin molded product made of the fiber reinforced resin. .

Furthermore, in the tenth aspect of the present invention, when a fiber-reinforced resin molded article using continuous fibers is produced according to the fourth or fifth aspect, a thermoplastic resin is used as the resin material, and the continuous fibers are elasticized. The outer peripheral surface of the core is disposed in a coated state, and the polymerization molding treatment is performed after the unpolymerized thermoplastic resin material is supplied onto the outer peripheral surface of the elastic core and impregnated in the continuous fibers. The resin molded product made of fiber reinforced resin is obtained.

As described above, by adopting the manufacturing method according to any one of the sixth to tenth aspects according to the molding resin material to be employed, the elastic medium as described in the fourth or fifth aspect is employed. A resin molded product made of a fiber reinforced resin reinforced with continuous fibers arranged in advance on the outer peripheral surface of the child can be manufactured with even better mass productivity.

By the way, regardless of reinforcing with the continuous fibers described in the above-mentioned fourth to tenth aspects, it is possible to mold the resin molded product with a resin material containing short fibers and long fibers which are not braided etc. is there.

That is, an eleventh aspect of the present invention, in the third-any method of manufacturing a resin molded product according to embodiment ten, the resin material reinforcing fibers discontinuous is blended, the elastic core A resin molded product is manufactured by molding on the outer peripheral surface.

The twelfth aspect of the present invention is the method for producing a resin molded product according to any one of the first to eleventh aspects, wherein the elastic core is deformed and the outer peripheral surface of the elastic core is deformed. The resin material is molded above.

  According to the manufacturing method of this aspect, the resin molding is carried out on the outer peripheral surface of the elastic core in a state where a more complicated shape is given by elastically deforming the elastic core in comparison with the original shape of the elastic core. Accordingly, it becomes possible to manufacture a resin molded product having a more complicated shape using an elastic core having a relatively simple shape.

In addition, in this aspect, for example, when a resin molded product reinforced with continuous fibers as described in any one of the fourth to tenth aspects is manufactured, the continuous fibers are arranged on the outer peripheral surface of the elastic core, and then, It is also possible to elastically deform according to the shape of the molded article for which the elastic core is intended and to resin-mold on the outer peripheral surface. As a result, the work for arranging the continuous fibers on the outer peripheral surface of the elastic core in a braided shape or the like can be further facilitated by performing the operation on the elastic core simplified than the shape of the molded product. become.

Furthermore, the deformation of the elastic core in this aspect may be a mode in which the shape in the length direction is changed at least at a part in the length direction. For example, the elastic core in a linear shape is held in a curved shape. And a mode of resin molding on the outer peripheral surface. In addition, as a modification of the elastic core in this aspect, the following thirteenth aspect can be adopted.

That is, in the thirteenth aspect of the present invention, in the method of manufacturing a resin molded product according to the twelfth aspect, the deformation of the elastic core changes the cross-sectional shape at least in a part of the length direction. Be done.

According to the above twelfth or thirteenth aspect, it is possible to mold a plurality of types of resin molded products having different curved shapes, cross-sectional shapes, etc. while adopting a common elastic core. Sharing of children can be achieved. This common use of elastic cores is not only for reducing the cost of manufacturing similar resin products, but also for example when manufacturing multiple types of resin prototypes and measuring and comparing properties such as strength. It is valid.

According to a fourteenth aspect of the present invention, in the method for producing a resin molded product according to any one of the first to thirteenth aspects, the elastic core has a branch portion, and a plurality of elastic cores are provided at the branch portion. The split elastic cores are separated from each other, and after the resin molded product is molded, each split elastic core is separated and extracted in the longitudinal direction to produce a resin molded product. is there.

  According to the manufacturing method of this aspect, a resin molded product having at least one branched structure can be manufactured according to the method of the present invention using an elastic core, and it is possible to manufacture a resin molded product having a more complicated shape. It becomes possible to apply the method of the present invention.

A fifteenth aspect of the present invention is a hollow resin-made elongated resin molded article, comprising a combination of a curved portion and a branch portion, and including the entire curved portion and the branch portion. The resin molded product is characterized by having a composite structure in which a resin material is reinforced with braided continuous fibers.

  The hollow structure resin molded product having the structure according to the present embodiment includes a reinforcing structure made of continuous fibers that could not be practically used in the prior art because it has both a curved portion and a branched portion. In addition, it has been possible to realize a complex and irregularly shaped hollow resin molded product having both a curved portion and a branched portion with a composite structure by continuous fiber reinforcement, so that various parts that have conventionally been difficult to be made into resins, such as automobiles Therefore, it is possible to use resin parts for the suspension arm. Incidentally, the product of the present invention, which is a hollow resin molded product having a complicated irregular shape and provided with a reinforcing structure by continuous fibers which has not existed in the past, can be manufactured by the manufacturing method according to the present invention described above.

  According to the present invention, by using an elastic core consisting of a composite of an elastic body and a continuous yarn, by applying a tensile force after molding of a resin material, the reduction of the sectional area of the elastic core in the longitudinal direction is made efficient. Thus, it is possible to obtain a hollow resin molded product having a hollow structure by extracting the elastic core.

The front view which shows the resin molded product as one Embodiment of this invention. FIG. 2 is a partially cutaway front view showing an elastic core used in manufacturing the resin molded product shown in FIG. 1 as an embodiment of the method of the present invention. Explanatory drawing for demonstrating one manufacturing process of the elastic core shown by FIG. Explanatory drawing which shows the state which distribute | arranged the reinforcement fiber to the surface of an elastic core obtained at 1 process of manufacturing the resin molded product shown by FIG. 1 using the elastic core shown by FIG. Explanatory drawing of the notch which shows the deformation | transformation state of the elastic core shown by FIG. FIG. 5 is an explanatory view showing a state in which the elastic core shown in FIG. 4 is set in the mold of the resin molded product shown in FIG. 1. Explanatory drawing which shows the process of extracting an elastic core from the resin molded product released after resin molding in the shaping | molding die shown by FIG. The front view which shows another example of the elastic core used in the case of manufacture of a resin molded product as another embodiment of this invention. Explanatory drawing for demonstrating the process of arranging a reinforcement fiber on the surface of the elastic core shown by FIG. 8 using a braider. It is explanatory drawing which partially cuts and shows the principal part of the resin molded product as another embodiment of this invention, Comprising: Explanatory drawing corresponded to the XX cross section in FIG. FIG. 11 is an explanatory view illustrating the manufacturing process of the resin molded product shown in FIG. 10;

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 shows a resin molded product 10 as an embodiment of the present invention. The resin molded product 10 has a hollow structure having a continuous hollow hole 12 inside, and has a different shape other than a simple straight pipe shape, having a branched portion 14 and a curved portion 16. The resin molded product 10 is used as a suspension member or the like for an automobile by fixing the mounting member to each end afterward or simultaneously with molding.

  More specifically, the resin molded product 10 of the present embodiment has a structure in which a long pipe portion 18 having a long axial length and a short short pipe portion 20 are integrally connected. And it has the bifurcated part 14 in which the short pipe part 20 was provided and branched from the lengthwise direction middle part of the long pipe part 18 at a substantially right angle. Moreover, the long pipe part 18 is made into the substantially U shape as a whole, and makes the center part of the length direction into the curved part 16 which curved in the semicircle shape.

  Further, the entire resin molded product 10 of the present embodiment is formed of a composite in which reinforcing fibers made of continuous fibers are disposed in a state of being embedded in a resin material as described later. One embodiment of a method of manufacturing such a resin molded product 10 according to the present invention will be described below.

  First, in order to provide a molding surface of the inner periphery of the hollow hole 12 of the resin molded product 10, an elastic core 26 as shown in FIG. 2 is manufactured and prepared. The elastic core 26 has a long axis 28 corresponding to the long pipe 18 of the resin molded product 10 and a short axis 30 corresponding to the short pipe 20 of the resin molded product 10.

  Each of the major axis portion 28 and the minor axis portion 30 is formed of an elastic material such as a rubber elastic body or an elastomer so as to be elastically deformable. The long shaft portion 28 can be elastically deformed into a shape including a curved portion corresponding to the curved portion 16 of the resin molded product 10. In addition, one axial end of the short shaft portion 30 is connected and fixed substantially at the center of the long axis portion 28 in the longitudinal direction.

  The major axis portion 28 and the minor axis portion 30 may have a solid shape, but in the present embodiment, they are in the form of a pipe having a hollow cross-sectional shape provided with the through holes 32 penetrating in the length direction. That is, elastic deformation in the direction in which the cross-sectional area is reduced is more efficiently generated in the pipe shape in comparison with the solid structure, and release of the resin molded product 10 described later becomes easier.

  Further, in the connecting portion 33 of the short shaft portion 30 with respect to the long shaft portion 28 corresponding to the branched portion 14 of the target resin molded product 10, the long shaft portion 28 and the short shaft portion 30 as a split elastic core are separated. The state and the connected state can be changed as appropriate. Specifically, for example, as shown in the drawing, the connecting bolt 34 inserted through the short shaft portion 30 is fixed to the fixed lids 36 and 36 disposed at both end openings of the short shaft portion 30. It is fastened, and further, one end of the connecting bolt 34 is detachably connected to the long axis portion 28.

  That is, the connecting bolt 34 projecting from one axial end side of the short shaft portion 30 is inserted into the through hole 32 through a connecting hole formed in the peripheral wall portion of the long shaft portion 28, and the long shaft portion The peripheral wall portion of the long shaft portion 28 is sandwiched between the fixed lid body 36 of the short shaft portion 30 and the connecting block 40 so as to be fixed by being screwed to the connecting block 40 disposed in the inner space 28. It has become. The connecting block 40 may be located inside the long shaft portion 28 and fixed to the long shaft portion 28, or may be removable from the long shaft portion 28. Further, the connecting bolt 34 is rotated by operating from the outer end portion of the connecting bolt 34 protruding outward from the short shaft portion 30, so that the connecting bolt 34 is detached from the connecting block 40, and the short shaft portion 30. Can be separated from the long shaft portion 28 at the connecting portion 33.

  In addition, the connection structure in the connection part 33 of the short shaft part 30 and the long shaft part 28 is not limited to a screw structure as illustrated, for example, a locking structure such as a snap mechanism such as a grommet, or a magnetic force. A separable connection structure such as an adsorption structure or a hook-and-loop fastener may be appropriately employed. Even in such various connection structures, the connection with the long shaft portion 28 on one end side of the short shaft portion 30 can be appropriately released by an operation such as pulling from the other end side of the short shaft portion 30. Can. However, the connection structure between the short shaft portion 30 and the long shaft portion 28 may be any structure as long as it can be held in an abutting state at the time of resin molding to be described later. It may be

  Further, if the connecting structure does not require the connecting bolt 34 penetrating the short shaft portion 30, the short shaft portion 30 can be bent and deformed, and even when the connecting bolt 34 is employed, the connecting bolt is used. The bending deformation of the short shaft portion 30 may be allowed by making at least the middle portion in the length direction of 34 into a deformable material.

  Further, among the long and short axial parts 28 and 30 constituting the elastic core 26, at least the long axis 28 having a large length is made of a composite of an elastic body and a continuous yarn. . In the present embodiment, the short shaft portion 30 is also composed of the same complex as the long shaft portion 28. That is, a plurality of continuous yarns 44 extending in the length direction are fixedly disposed on the long shaft portion 28 and the short shaft portion 30 with respect to the elastic material 42 constituting the long shaft portion 28 and the short shaft portion 30.

  The continuous yarn 44 exerts a tensile force in the length direction of the elastic material 42, and at least the tensile force exerted from one end portion in the length direction can be efficiently exerted on substantially the entire length direction. A material having a higher tensile rigidity than the elastic material 42 is used, and for example, resin fibers such as polyamide and polyester are preferably used, but an aramid fiber having higher tensile strength and rigidity can also be used.

  Further, the continuous yarn 44 is inclined with respect to the length direction so that a deformation displacement force in the diameter reduction direction can be efficiently transmitted in the length direction of the elastic member 42 by applying a tensile force. Or arranged with a predetermined braided structure. Specifically, for example, a braided structure in which a plurality of continuous yarns 44 are braided with each other in the longitudinal direction by a braid structure is suitably adopted, and continuous yarns 44 are arranged in a spiral at a predetermined lead angle in the longitudinal direction. Alternatively, a spiral structure in which a plurality of continuous yarns 44 extending in a spiral shape by being inclined in directions different from each other is disposed in an overlapping manner is preferably employed. When a braid structure or a spiral structure is employed, the tensile force is set by setting the inclination angle of the continuous yarn 44 with respect to the axial direction of the elastic material 42 to an angle close to the stationary angle or a predetermined amount larger than that. It is also preferable to improve the efficiency of the action and transmission of the force in the cross-sectional reduction direction of the elastic member 42 accompanying the action of.

  The major axis 28 and the minor axis 30 made of such a composite can be molded by filling an elastic material in a molding cavity in which the continuous yarn 44 is disposed, as shown in FIG. It can manufacture more efficiently using the shaping | molding apparatus which is.

  That is, a hollow or solid (hollow in this embodiment) inner layer elastic material 50 is continuously supplied to the brader 52, and a plurality of continuous yarns 44 are supplied from the braider 52 onto the surface of the inner layer elastic material 50. On the other hand, the intermediate material 56 including the blade 55 in which a plurality of continuous yarns 44 are braided with a braided structure so as to cover the surface of the interior elastic material 50 is obtained continuously by being taken up by the take-up machine 54. As such a radar 52, it is possible to use, for example, a device known as a braiding device around a mandrel, and in general, continuous yarns respectively supplied from a plurality of bobbins provided on a bobbin carrier Is fed to the composition point of the braid via the guide ring, and a structure in which braided braided blades are braided by a plurality of continuous yarns being crossed and pivoted around a core body such as a mandrel etc. There is.

The intermediate material 56 continuously drawn from the take-up machine 54 by braiding the continuous yarn 44 on the surface of the inner-layer elastic material 50 with the braider 52 is supplied to an elastic material extrusion molding machine 58. Then, in the extrusion molding machine 58, the outer layer elastic material 60 covering the outer peripheral surface of the intermediate material 56 is molded using an elastic material supplied from the outside, so that the inner layer elastic material 50 and the outer layer elastic material 50 are integrally laminated. A continuous cylindrical composite 62 is manufactured in which a plurality of continuous yarns 44 extending in a braided structure continuously in the length direction are arranged and fixed between the layer elastic members 60 and fixed.

  The composite 62 is continuously taken out of the extrusion molding machine 58 by the take-out machine 64, and if necessary, the inner and outer layer elastic members 50, 60 are subjected to an immobilization treatment such as polymerization treatment or vulcanization treatment. A continuous tubular molded product 65 made of a composite of the material 42 and the continuous yarn 44 having a blade structure is obtained. Thereafter, the tube-shaped molded article 65 is cut into an appropriate length, whereby the above-mentioned long axis 28 and short axis 30 can be obtained.

  Then, using the elastic core 26 shown in FIG. 2 formed by combining the major axis 28 and the minor axis 30 thus obtained, a fiber-reinforced resin molded article 10 shown in FIG. 1 is manufactured. In this case, after arranging reinforcing fibers on the outer peripheral surface of the elastic core 26, resin molding is carried out on the outer peripheral surface of the elastic core 26 to obtain a fiber reinforcement having a composite structure of the reinforcing fiber and the resin material. A resin molded product 10 made of resin is obtained.

  Specifically, as shown in FIG. 4, the reinforcing fiber is appropriately braided so as to cover the entire outer peripheral surface of the major axis portion 28 and the minor axis portion 30 constituting the elastic core 26. To form a reinforcing fiber layer 66. The reinforcing fiber layer 66 is appropriately selected from the material, fiber form, braided structure and the like according to the characteristics required for the resin molded product 10, and is not particularly limited. A reinforcing fiber layer 66 in which reinforcing fibers such as certain carbon fibers, glass fibers, and polymer fibers are braided in a braided structure is preferably employed.

  The reinforcing fiber layer 66 having a braid structure uses, for example, a brader as shown in FIG. 3 while the elastic core 26 is positioned on the center of the knitting composition to which a plurality of reinforcing fibers are supplied and moved in the length direction. The braided reinforcing fiber layer 66 can be formed by forming a braid on the outer peripheral surface of the elastic core 26. The reinforcing fiber layer 66 may have a single-layered blade structure, but may be reciprocated in the longitudinal direction of the major axis 28 and the minor axis 30 of the elastic core 26 to form a multi-layered blade structure. Is also possible.

  Further, since the elastic core 26 is capable of elastically deforming the longer major axis portion 28, even if it has a branched structure, the obstacle in relation to the supply line etc. of the reinforcing fiber when braiding using a braider It is possible to escape by curving or bending the part to be. In particular, in the present embodiment, not only the long shaft portion 28 but also the short shaft portion 30 can be elastically deformed. Therefore, the branching structure and the overall shape of the elastic core 26 are a great obstacle in forming the reinforcing fiber layer 66. Can be avoided. Further, even after the major axis portion 28 and the minor axis portion 30 are bent and deformed, they can be quickly restored to the original shape on the basis of their elasticity, so that there is no hindrance to subsequent resin molding and the like. Furthermore, since the reinforcing fiber layer 66 formed on the outer peripheral surface of the long axis portion 28 and the short axis portion 30 also has a small diameter and deformable fiber braid structure, the long axis portion 28 or the short axis portion 30 Can be deformed and restored following the above.

  Therefore, as shown in FIG. 5, the elastic core 26 having the reinforcing fiber layer 66 formed on the outer peripheral surface is elastically deformed in the longitudinal direction of the long axis portion 28 to be an outer peripheral surface to be a resin molding surface. Along with the reinforcing fiber layer 66, a shape corresponding to the intended resin molded product 10 (see FIG. 1) can be obtained.

  Then, as shown in FIG. 6, the elastic core 26 is arranged in the molding cavity of the molding die 70 of the resin material, and is elastically deformed into a shape corresponding to the target resin molded product 10 (see FIG. 1). Position and hold in the state of being set. Thereafter, the mold 70 is closed, the resin material is filled on the reinforcing fiber layer 66 on the outer peripheral surface of the elastic core 26 by injection or the like, and after cooling, the mold is opened and removed to remove the reinforcing fiber layer 66. Can be compounded in a state of being embedded in a resin material to form a fiber-reinforced resin molded article 10.

  Here, as the elastic core 26, a hollow structure having a through hole 32 is employed in the present embodiment, and therefore, the non-compressible and indeterminate filler 74 is filled in the through hole 32 in advance. (See FIG. 5). The filler 74 can be a liquid or a solid granular material of several mm or less so that the through hole 32 can be easily filled and removed, and deformation of the long shaft portion 28 is allowed in the filled state. Desirably, water, sand grains, etc. can be adopted. Filling the hollow inside of the elastic core 26 with the filler 74 prevents the buckling deformation during the bending deformation, stabilizes the bending deformation shape, or deforms due to the resin pressure filled in the molding cavity 72. There is an advantage that can be prevented. On the other hand, when filling the inside of the hollow of the elastic core 26 with the filler, for example, if the filling pressure of the filler such as a liquid is increased so that the elastic core 26 is expanded, the elastic core 26 is removed from the mold. At the same time, it is also possible to release the filling pressure and return the elastic core 26 to its original size so that removal can be performed more easily.

  Incidentally, the filling material 74 can be appropriately supplied and discharged to and from the hollow interior of the elastic core 26, and the major axis 28 and the short axis 30 of the elastic core 26 can be maintained so as to be held in a closely packed state. Each opening is sealed by an end cap 76 that can be opened and closed.

  Thereafter, by removing the elastic core 26 from the resin molded product 10 taken out of the mold 70 shown in FIG. 6, the target resin molded product 10 is obtained. When the elastic core 26 is removed, at least one end cap 76 is opened to remove the filler 74 from the hollow interior, and the connection by the connection bolt 34 is released, and the long shaft portion 28 and the short shaft portion 30 are removed. Separate. Subsequently, as shown in FIG. 7, each of the long shaft portion 28 and the short shaft portion 30 is pulled out from the resin molded product 10 by applying a tensile force from one end side in the length direction. Can be removed.

  At that time, since the long shaft portion 28 and the short shaft portion 30 have a composite structure of the elastic material 42 and the continuous yarn 44, the tensile force exerted on one end side in the length direction is continuous in the length direction. The continuous yarns 44 arranged in this way are effectively applied to a sufficiently long area toward the other end in the longitudinal direction. Since the long shaft portion 28 and the short shaft portion 30 to which a tensile force is exerted in the length direction, a diameter-reducing deformation with a reduced cross-sectional area is generated in a sufficiently long region together with the elongation deformation in the length direction. In particular, in this embodiment, since the long shaft portion 28 and the short shaft portion 30 have a hollow cross-sectional shape, the cross-sectional reduction deformation is more efficiently generated.

  Thus, in the long shaft portion 28 and the short shaft portion 30, the tensile force exerted from one end side in the length direction is efficient over a sufficiently long region with the expansion deformation in the length direction and the cross-sectional reduction deformation. As a result of being transmitted as a result, the elastic core 26 is sufficiently long from the inner circumferential surface of the resin molded product 10 as in the long pipe portion 18 and the short pipe portion 20, even if it is curved or deformed in the radial direction. As a result, the outer peripheral surfaces of the long shaft portion 28 and the short shaft portion 30 can be forcibly separated. Therefore, after molding of the resin molded article 10, the long tube part 18 and the short tube part of the resin molded article 10 are pulled by pulling the long axis part 28 and the short axis part 30 of the elastic core 26 from one end side in the length direction. The elastic core 26 can be pulled out easily and quickly from 20, and the resin molded product 10 can be released.

  After or before releasing from the elastic core 26, the resin molded product 10 is appropriately subjected to post-processing, such as edge treatment of the end, as needed, to obtain a product.

  Further, since the long shaft portion 28 and the short shaft portion 30 extracted from the resin molded product 10 can be quickly restored to the original shape based on their own elasticity, they are subjected to confirmation processing such as cleaning and inspection as necessary. The elastic core 26 can be used repeatedly in the manufacturing process of a resin molded product.

  Therefore, according to the manufacturing method as described above, the elastic elastic core 26 formed of a composite of the elastic material 42 and the continuous yarn 44 is employed to resin-mold on the outer peripheral surface, and after elastic resin molding, It is possible to easily remove the child 26 and manufacture the resin molded product 10 having a hollow structure with excellent mass productivity.

  In the embodiment, the resin made of fiber reinforced resin is filled by filling the molten resin material in a state in which the reinforcing fiber layer 66 consisting of continuous fibers is braided in advance on the outer peripheral surface of the elastic core 26 set in the molding cavity 72. Although the case where the molded product 10 is manufactured is illustrated, the reinforcing fiber layer 66 is not essential in the present invention, and a resin molded product which is not fiber reinforced can also be manufactured. In addition, by filling a resin material in which discontinuous reinforcing fibers consisting of short fibers or long fibers are mixed into the molding cavity 72, it is also possible to manufacture a resin molded product consisting of a fiber reinforced resin by non-continuous fibers. As such non-continuous reinforcing fibers, for example, any of glass fibers, aramid fibers, high density polyethylene fibers, carbon fibers and the like can be adopted.

  Further, as in the above embodiment, when the resin material is injected into the molding cavity on the outer peripheral surface of the elastic core 26 covered with the reinforcing fiber layer 66 to form the fiber reinforced resin product, the reinforcing fiber layer 66 and the resin are In order to stably obtain a composite structure with the material, the fluidity of the resin material injected into the molding cavity is required. Therefore, after injection molding of an unpolymerized resin material having large fluidity in an unpolymerized state into a molding cavity, it is also possible to carry out a polymerization treatment such as heating in the molding cavity for resin molding.

  Alternatively, the thermoplastic resin, which is formed into a continuous fiber in advance, may be arranged in a coated state on the outer peripheral surface of the elastic core 26 together with the reinforcing fiber (reinforcing fiber layer) 66. As described above, the resin material is disposed on the outer peripheral surface of the elastic core 26 so as to be entangled with the reinforcing fiber 66 as a continuous fiber, and the resin material is heated and melted to efficiently convert the resin material into the reinforcing fiber 66. Thus, it is possible to stably form the fiber reinforced resin having a composite structure as an impregnated state.

  Moreover, after arranging the thermoplastic resin in powder form and arranging the continuous fiber to which the thermoplastic resin is attached as a reinforcing fiber 66 in a braided state on the surface of the elastic core 26, the resin material is heated and melted. A fiber reinforced resin having a composite structure can also be formed by efficiently impregnating the reinforcing fibers 66.

  In this way, the thermoplastic resin is made into a continuous fiber form or powder form and is in close contact with the surface of the reinforcing fiber 66 so as to be entangled with the reinforcing fiber 66 before molding by heating and melting, or entangled with the reinforcing fiber 66. By setting it, it becomes possible to stably obtain a resin molded article of a composite structure integrated with the reinforcing fiber, even in the case of a resin material which is difficult to secure sufficient fluidity.

  When a thermoplastic resin is used as the resin material of the resin molded product 10, a prepreg made of a fiber-reinforced resin sheet previously formed into a sheet or tape is used, and the prepreg is used as the outer peripheral surface of the elastic core 26. The fiber reinforced resin is arranged by arranging it in such a manner as to be braided, superposed and attached, or arranged to be wound, covering the entire surface of the elastic core 26 and then heating and melting it to be integrated. It is also possible to mold the molded product 10.

  On the other hand, when a thermosetting resin is used as the resin material of the resin molded product 10, it is easy to obtain good fluidity in the resin material before the curing treatment, so that it is mixed with prior reinforcing fibers like a thermoplastic resin. It is also possible to eliminate the need for processing and high filling pressure into the molding cavity. Specifically, for example, a continuous fiber impregnated with a thermosetting resin material is braided on the outer peripheral surface of the elastic core 26 and then subjected to a curing treatment to form a fiber-reinforced thermosetting resin. It is also possible to obtain a product, and a thermosetting resin molding reinforced with fibers by braiding continuous fibers on the outer peripheral surface of the elastic core 26 and then impregnating with a thermosetting resin material and curing treatment. It is also possible to obtain goods. In a more specific example, after the continuous fiber impregnated in advance with the resin material is braided on the outer peripheral surface of the elastic core 26 having an initial shape other than the curved shape intended for the molded article, the elastic core 26 is The resin is cured in a state where it is curved and deformed into a target shape, and thereafter the elastic core 26 is removed from the resin molded product and then demolded to obtain the target resin molded product. In addition, after braiding a continuous fiber impregnated with a resin material on the outer peripheral surface of the elastic core, a resin sheet such as a sheeting tape is superimposed and wound as needed, and then the elastic core is curved into a target shape. It is also possible to perform a curing process by deforming, and thus the degree of freedom in adjusting the thickness of the resin layer can be improved by overlapping the resin sheet on the outer peripheral side or inner peripheral side of the continuous fiber braided layer. .

  Furthermore, in the embodiment, the elastic core 26 is bent and deformed by applying an external force as shown in FIGS. 5 to 6 from an initial shape in which no external force is applied as shown in FIG. While the resin molded product 10 is formed by performing resin molding on the outer peripheral surface while being held in a state, for example, as shown in FIG. 8, the elastic core 26 having a target shape having a curved portion in advance is formed. It is also possible to form ′.

  Thus, if elastic core 26 'having a curved portion and a connecting portion 33' is adopted, it is not necessary to deform and hold it in a target shape at the time of resin molding, so that the resin molding operation is simplified and the shape is stabilized. Can be Further, even the elastic core 26 ′ having a curved portion in the initial shape can be elastically deformed, and the reduction of the cross-sectional area when the tensile force is applied is effectively exerted in the length direction. Thus, as in the above-described embodiment, the long shaft portion 28 ′ and the short shaft portion 30 ′ can be pulled out from the resin molded product 10 by applying a tensile force after molding the resin molded product 10 on the outer peripheral surface. .

  Also, since elastic core 26 'having a curved portion is also allowed to be elastically deformed, for example, as shown in FIG. 9, a reinforcing fiber is provided on the outer peripheral surface of elastic core 26' using a braider 80 or the like. Even when braiding the elastic core 26 ', it is possible to avoid interference with a plurality of reinforcing fibers supplied to the knitting composition point while applying elastic deformation by appropriately stretching each part of the elastic core 26'. The braiding operation of the reinforcing fiber on the surface of the core 26 'can be facilitated.

In the elastic core 26 in the embodiment, the long axis portion 28 and the short axis portion 30 are formed of an elastic material, and therefore, when resin is formed, the elastic core 26 is bent and deformed in the length direction to form the resin molded article 10 In addition to forming 16, it is also possible to change and set the cross-sectional shape of the resin molded product 10 by elastically deforming the cross-sectional shape. Specifically, for example, in the short axis portion 30 of the circular outer peripheral surface, by molding a resin molded article 10 in a state of exerting a pressing force in the axis-perpendicular direction brought held oval outer peripheral surface of the short tube portion 20 It is also possible to obtain the resin molded product 10 having a cross-sectional shape of an elliptic cylinder.

  As described above, according to the present invention, by adopting the elastically deformable elastic core 26, the resin molded product having another shape in which the shape, the cross-sectional shape, etc. of the curved portion are different without replacing the elastic core 26 or the like. It becomes possible to shape.

  In the embodiment described above, the resin molded product 10 including the branched portion 14 and the curved portion 16 is manufactured using the branched elastic core 26 having the connecting portion 33 of the long axis portion 28 and the short axis portion 30. Although the case has been described, the method of the present invention can also be applied to the case of molding a hollow resin molded article having no branched portion using an elastic core having substantially only a long axis. Moreover, also when manufacturing the resin molded product provided with two or more branched parts and several curved parts, this invention method is applicable by forming an elastic core with a branch structure corresponding to it.

  Furthermore, by having at least one connecting portion 33, in the elastic core configured with a plurality of longitudinal portions such as the long shaft portion 28 and the short shaft portion 30, each longitudinal portion has a hollow cross-sectional shape. Even in this case, the hollow interiors do not need to communicate with each other, and may have independent hollow cross-sectional shapes. In addition, the cross-sectional shape of the elastic core 26 is not limited to the solid circular or hollow circular cross section as illustrated, but may be a solid or hollow oval or polygon according to the required resin molded product. Various cross-sectional shapes can be employed.

  Further, with respect to the major axis portion 28 formed of the composite of the elastic member 42 and the continuous yarn 44 as described above, when the minor axis portion 30 is sufficiently short or the one side in the axial direction is tapered. In such a case, it is possible to form the short shaft portion 30 with an elastic core consisting of a single piece of an elastic material such as rubber or the like, and further short when no curved portion is set in the short shaft portion 30. It is also possible to form the shaft portion 30 with a hard core such as metal.

  By the way, the resin molded product 10 having a structure according to the present invention is a longitudinal resin molded product having a hollow structure as shown in the above-described embodiment, and includes both a curved portion 16 and a branched portion 14. The present invention is intended for a composite structure in which a resin material is reinforced by reinforcing fibers 66 made of continuous fibers braided over the entire length including the curved portion 16 and the branched portion 14.

  Since such a resin molded product 10 has a complicated shape including the curved portion 16 and the branched portion 14, conventionally, it can be formed with a composite structure having reinforcing fibers composed of braided continuous fibers. In the case of braiding on the outer peripheral surface, it is possible to appropriately bend the respective portions to escape from the braided fiber, as a result of providing the elastically deformable elastic core 26 as described above. It is obtained. Therefore, it can be said that such a complex irregularly shaped resin molded article 10 having a structure according to the present invention is an example of a product that can only be realized by the provision of the method of the present invention.

  Furthermore, when manufacturing a resin molded product according to the present invention, other members or other parts that are separately manufactured are embedded, fixed, or fixed so as to be cast together. It is also possible to provide it. At that time, it is also possible to facilitate handling such as positioning by fixing or overlapping such other members or other parts with respect to the elastic core, and other members or other parts after resin molding By separating and molding the elastic core from the above, it is possible to obtain a resin molded article integrally provided with other members and other parts.

  At this time, as in the case of the resin molded product 10 of the embodiment, when making a fiber reinforced resin product reinforced with continuous fibers, the continuous fiber disposed so as to cover the outer peripheral surface of the elastic core is the above other member In addition, by arranging so as to cover the outer peripheral surface of other parts, it is also possible to obtain a resin molded product in which fiber reinforcement is integrally performed around the other members and other parts.

  For example, as shown in FIG. 10, mounting of separate members to the end of the resin molded article 10 of the embodiment (one end in the longitudinal direction of the long tube portion 18 in the embodiment shown) It is possible to obtain a resin molded product 10 ′ having a structure in which a rubber bush 84 as a part is integrally provided.

  For example, as shown in FIG. 11, when manufacturing such a resin molded product 10 ', a separately formed rubber is formed on one end face of the long-axis portion 28 of the elastic core 26 obtained according to the embodiment. The bushes 84 are arranged so as to overlap each other. The structure of the rubber bush 84 is not limited in any way. For example, as is well known as a suspension bush or the like, a cylindrical inner metal fitting with respect to the inner peripheral surface of the thick cylindrical vibration-proof rubber 86. One obtained by vulcanizing and bonding 88 can be employed.

  The elastic core 26 is provided with the reinforcing fiber 66 braided or the like so as to cover the outer peripheral surface as described in the above embodiment. At this time, the rubber disposed on the end of the elastic core 26 is provided. Also for the bush 84, the reinforcing fiber 66 is braided or the like so as to cover the outer peripheral surface of the vibration-proof rubber 86, and reinforced so as to continuously cover both outer peripheral surfaces of the elastic core 26 and the vibration-proof rubber 86. Fibers 66 are disposed. After that, when molding a resin material having a composite structure in which the reinforcing fibers 66 are integrated in an embedded state by performing resin molding, the resin is covered in a state covering the whole from the outer peripheral surface of the elastic core 26 to the outer peripheral surface of the vibration isolating rubber 86. As shown in FIG. 10, the outer cylindrical portion that covers the outer peripheral surface of the vibration isolating rubber 86 of the rubber bush 84 integrally with the long tube portion 18 and the short tube portion 20 having a hollow structure is formed. 90 can be integrally formed. Incidentally, after resin molding, as in the embodiment described above, the long axis portion 28 and the short axis portion 30 of the elastic core 26 are pulled out and released to integrally form a target fiber reinforced hollow structure. A resin molded product 10 'is obtained.

  Therefore, the resin molded product 10 ′ thus obtained has a hollow predetermined shape including the branching portion 14 and the curved portion 16, and a structure in which the rubber bush 84 is integrally assembled simultaneously with the molding. It is being done. In this embodiment, in particular, since the peripheral wall portion of the long pipe portion 18 and the outer cylindrical portion 90 of the rubber bush 84 are reinforced by a continuous reinforcing fiber to form a resin structure integrally formed, Not only is the number of attachment steps reduced to facilitate manufacture, but also the strength of the assembly portion of the rubber bush 84 can be advantageously secured.

  The resin molding on the outer peripheral surface of the elastic core 26 and the rubber bush 84 is, for example, as shown in FIG. After setting a braided continuous reinforcing fiber so as to cover the outer peripheral surface of 84 in a molding cavity, it is also possible to supply a resin material to the molding cavity for molding.

  Further, as described above, when an epoxy resin or the like is adopted, a resin sheet-like prepreg made of a prepolymer integrated with continuous reinforcing fibers is used, and the outer periphery of the elastic core 26 or the rubber bush 84 is made of such a prepreg. After covering the surface, it is also possible to form by crosslinking network formation with an epoxy group by curing treatment with heat or the like. In the case of adopting a molding method using prepreg, the prepreg is covered so that the outer peripheral surfaces of the elastic core 26 and the rubber bush 84 are continuously covered after the entire circumference of the rubber bush 84 is covered with the prepreg. By arranging, it is also possible to form a cylindrical outer cylindrical portion 90 which covers the entire circumference of the rubber bush 84.

  In addition, although not listed one by one, the present invention can be implemented in an embodiment to which various changes, modifications, improvements, etc. are added based on the knowledge of those skilled in the art, and such embodiments are the present invention. It goes without saying that all are included in the scope of the present invention without departing from the spirit of the present invention.

10: resin molded product, 12: hollow hole, 14: branch portion, 16: curved portion, 18: long tube portion, 20: short tube portion, 26: elastic core, 28: long axis portion, 30: short shaft portion 33: connecting part, 34: connecting bolt, 42: elastic material, 44: continuous yarn, 66: reinforcing fiber, 70: molding die, 72: molding cavity

Claims (14)

A method for producing a longitudinal resin molded product having a hollow structure,
It is an elastic core having a longitudinal hollow cylindrical shape composed of a composite of an elastic body and a continuous yarn , and the continuous yarn has a braided structure or a spiral structure and is embedded in an intermediate portion in the thickness direction of the elastic body. By forming a resin material on the outer peripheral surface of the elastic core by using the one continuously extending in the circumferential direction of the elastic body and continuously extending over the entire length in the longitudinal direction by being integrated , A method for producing a resin molded product, characterized in that a longitudinal resin molded product having a hollow structure is obtained by applying a tensile force to one end in the length direction of the elastic core and extracting it in the longitudinal direction. . The method for producing a resin molded product according to claim 1 , wherein when molding the resin material on the outer peripheral surface of the elastic core, an incompressible, indeterminate, incompressible filler is filled in the hollow. Method for producing a resin molded article according to claim 1 or 2 to form the resin molded article of the resin material with fibers reinforced fiber reinforced resin. 4. The resin according to claim 3 , wherein reinforcing resin made of continuous fibers is arranged on the outer peripheral surface of the elastic core, and the resin molded product made of the fiber reinforced resin reinforced with the reinforcing fiber is obtained by molding the resin material. Manufacturing method of molded products. The manufacturing method of the resin molded product of Claim 4 which distribute | arranges so that the said continuous core may be covered with a braid shape on the outer peripheral surface of this elastic core, curving and deforming the said elastic core. While using a thermosetting resin as the resin material,
After the continuous fiber impregnated with the thermosetting resin is disposed on the outer peripheral surface of the elastic core in a coated state, the thermosetting resin is cured to form the resin molded product made of the fiber reinforced resin. A method for producing a resin molded product according to claim 4 or 5 . While using a thermosetting resin as the resin material,
The continuous fibers after placed in covering state on an outer peripheral surface of the elastic core, from the fiber reinforced resin by upon molding of the thermosetting resin impregnated with a thermosetting resin to the continuous fibers curing treatment method for producing a resin molded article according to claim 4 or 5 to obtain the resin molded article formed. Using a thermoplastic resin as the resin material,
After the fibrous thermoplastic resin is disposed on the outer peripheral surface of the elastic core together with the continuous fibers in a coated state, the thermoplastic resin is melt-molded to form the resin molded product made of the fiber-reinforced resin. A method for producing a resin molded product according to claim 4 or 5 . Using a thermoplastic resin as the resin material,
After the powdery thermoplastic resin is attached to the continuous fibers and disposed in a covering state on the outer peripheral surface of the elastic core, the thermoplastic resin is melt-molded to form the fiber reinforced resin. The method for producing a resin molded product according to claim 4 or 5 , wherein a molded product is obtained. Using a thermoplastic resin as the resin material,
The continuous fibers are arranged in a coated state on the outer peripheral surface of the elastic core, and polymerized after the unpolymerized thermoplastic resin material is supplied onto the outer peripheral surface of the elastic core to impregnate the continuous fibers. The method for producing a resin molded product according to claim 4 or 5 , wherein the resin molded product made of the fiber reinforced resin is obtained by molding treatment. The method for producing a resin molded product according to any one of claims 3 to 10 , wherein the resin material mixed with discontinuous reinforcing fibers is molded on an outer peripheral surface of the elastic core. The method for producing a resin molded product according to any one of claims 1 to 11 , wherein a resin material is molded on an outer peripheral surface of the elastic core in a state where the elastic core is deformed. The method for producing a resin molded product according to claim 12 , wherein the deformation of the elastic core changes a cross-sectional shape in at least a part of the length direction. The elastic core has a branch portion, and a plurality of longitudinal split elastic cores are connected to the branch portion so as to be separable. The method for producing a resin molded product according to any one of claims 1 to 13 , wherein the resin molded product is separated and extracted in each longitudinal direction.

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